Reassembling a Honda dual piston brake caliper – CX500, GL500, CX650, GL650 and others

OK, so you have dismantled, cleaned and assessed your calipers and now you want to put in the rebuild kit and get the lot reassembled. Here’s how.

Make sure that your seal grooves are completely free from any debris:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab your new seals – per piston there are two, 45209-166-006 (eBay US) and 45109-166-006 (eBay US):

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the larger of the two and coat it in brake fluid – wear protection, you don’t really want brake fluid on your skin/eyes/etc.:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Insert it into the larger groove:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

The skinnier seal has two different faces; the outside (what sits against the caliper):

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

The inside – which sits against the piston:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Coat it with brake fluid and install it into the thinner seal groove:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the brake piston – these are machined stainless examples – lubricate it with brake fluid and install it with the opening facing outward towards the brake pad:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Repeat the whole process for the other side:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab your brake pads:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab your brake pad spring – this one needs a clean but it’ll do to demonstrate:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Locate the little hole in the caliper for the tang to go into:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

This is the bit that goes in there:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Install it like so:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the brake pad retaining pins:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

They get pushed in the holes from the side that the brake banjo is on – don’t push them in the whole way – about so far:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the brake pads:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Slide the brake pads on, pad side facing away from the pistons:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Push the other pad in, pad side facing the other pad, then push the two brake pad retaining pins through the whole way:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Now that they are pushed through we need to put a metal bracket in place – the brake pin retainer bracket – to stop them from moving; it goes here:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

The bracket in question:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

You need a little bolt:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

It sits over the end like so:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Install the bolt:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the seals:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Grab the slide pin and lubricate it with brake grease:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Install the seal in the aperture – this one:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

…and then push the slide pin in – it’s easier than putting the seal on the pin and then trying to get the seal to fit the caliper:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Slide it through the aperture:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Install the other seal – it’s easier if you push the slide pin towards the side that you’re installing the seal on:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Return the slide pin to the center:

Here's how to use a rebuild kit and reassemble the Honda CX500 twin piston calipers as found on the Honda CX500, GL500, CX650 and GL650 motorcycles and others.

Rebuild kit completely installed!

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